KRAL Pump Stations. DKB Series.

Catalog

DKB Edition 03/2010

2

DKB Edition 03/2010

Catalog

KRAL Pump Stations – DKB Series

Table of contents Description

□ □

□

Structure

5

Function description ▪ Functional principle ▪ Reversing valve ▪ Expansion valve ▪ Pressure measurement

6 6 6 6 6

Type code

7

Technical data

□ □ □ □ □ □ □

Operational limits

9

Materials

9

Performance data ▪ Performance data DKB

10 10

Required NPSH values

10

Weights

12

Filling volume

12

Noise levels

12

Dimensioned drawings

□ □ □ □

Dimensions DKB Standard

13

Dimensioned drawings DKB Standard

13

Dimensions DKB with oil pan

14

Dimensioned drawings DKB with oil pan

14

Options

□ □ □ □ □ □ □

Overview

15

Suction-side pressure monitoring

16

Temperature monitoring

17

Leak oil monitoring

18

Pressure switch ▪ Specifications of the pressure switch

19 19

Oil pan

21

Heating system ▪ General ▪ Electric heating system ▪ Fluid heating system

22 22 22 24

General drawings

□ □

General drawings

25

Spare parts

28

Catalog

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4

DKB Edition 03/2010

Catalog

Description

Description

Structure Structure

3

2

1

5

1 4

Fig. 1 1 2

Structure

Pumps Reversing valve (lever)

3

Pressure-side pressure gauge

4 5

Suction connection Pressure connection

PI

TI M

PI

Suction Side

M

Pressure Side

TI

PI Fig. 2

Catalog

Hydraulic scheme

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Description

Function description Function description Functional principle The pump stations of the DKB series are suitable for the parallel operation of two KRAL pumps of the K or L series. The functional description of the pumps is contained in the associated pump operating instructions. The station is connected to the piping system by means of the suction connection 4 at the front of the station. Depending on the position of the reversing valve 2, the left-hand, the right-hand or both pumps are connected to the suction connection. There the pressure of the pumped liquid is increased which finally returns to the station through the pressure connection of the pump. Via a return valve the liquid flows through the reversing valve finally to the pressure connection 5, through which the liquid leaves the station again. Reversing valve

Fig. 3

Positions of the reversing valve

If the lever of the reversing valve 2 is in one of the two side positions, the respectively other line of the station is separated from the liquid circuit so that the pump of this line can be dismantled. If the lever is in the center position, both lines are connected to the liquid circuit. The delivery rate can thus be increased through parallel operation of the two pumps. If only one pump is being operated, the second pump can be cut in automatically if the delivery rate or the pressure drops at the active line. In order to ensure a uniform distribution of the operating hours, an interval-controlled automatic switch-over between the two pumps is also possible in this valve position. The return valves ensure that the respective pump that is stopped does not begin to rotate backwards.

Expansion valve The liquid volume in the respectively blocked line of the station could result in an impermissibly high inner pressure due to heating up through thermal expansion. In order to prevent this, the cylinder of the reversing valve contains two small spring expansion valves that vent any overpressure in the respectively active line of the station. Pressure measurement A pressure gauge 3 is located in the center of the station in order to monitor the delivery pressure. The pressure gauge is always connected to the pressure side of the station and is thus independent of the position of the reversing valve 2. In order to monitor the pressure on the suction sides of the two pumps, two further pressure gauges can be mounted optionally.

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Catalog

Description

Type code Type code

2

4

DKB- 1000.BA.00001 1

3

5

1 2 3 4 5

Model Size Seal type Heating system Version index

Item Designation

Type

1

Model

DKB: Pressure build-up up to 16 bar

2

Size

Corresponds to flow rate in [l/h] at motor speed

3

Seal type

A: Standard mechanical seal B: Mechanical seal of hard material C: Standard radial shaft seal D: Magnetic coupling E: Mechanical seal with quench F: Radial shaft seal, high-temperature model X: Special version

4

Heating system A: Standard, without heating system B: With electrical heating system in the block C: With fluid heating system in the block D: With electrical heating system in the block and at the pumps E: With fluid heating system in the block and at the pumps

5

Catalog

Version index

For internal administration

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Description

Type code

8

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Catalog

Technical data

Technical data

Operational limits Operational limits DKB Differential pressure max. [bar]

16

Temperature max. [°C]

180

Temperature min. [°C] for pump materials

–20

2

Viscosity [mm /s] min.–max.

2–10000

Inlet pressure max. [bar]

6

Materials DKB Material

□

Station block

Casing

□

Catalog

Material No.

EN-GJS-400-15 EN-JS1030

Pump

Casing

EN-GJS-400-15 EN-JS1030

Screw set

16MnCrS5

Flange cover

EN-GJS-400-15 EN-JS1030

End cover

EN-GJS-400-15 EN-JS1030

1.7139

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Performance data

Pump size KFT

Performance data DKB Station size DKB

Technical data

Performance data

Flow rate [l/h] at 5 bar 2

Flow rate [l/h] at 10 bar 2

Rotation speed 10 mm /s [min-1]

90 mm /s

10 mm2/s

90 mm 2/s

50 Hz

60 Hz

50 Hz

60 Hz

50 Hz

60 Hz

50 Hz

60 Hz

50 Hz

60 Hz

3000

55

1450

1750

2950

3675

3300

4030

2720

3450

3220

3945

4000

74

1450

1750

3855

4790

4275

5205

3590

4520

4175

5110

4500

85

1450

1750

4335

5375

4770

5805

4060

5100

4665

5705

5500

105

1450

1750

4985

6230

5650

6890

4550

5800

5495

6740

6000

55

2900

3500

6460

7910

6815

8265

6230

7685

6730

8180

6500

118

1450

1750

6225

7700

6810

8285

5850

7325

6670

8145

8000

74

2900

3500

8370

10235 8780

10650 8100

9965

8685

10550

9000

85

2900

3500

9350

11420 9780

11855 9070

11145 9675

11750

11000 105

2900

3500

11010 13505 11675 14165 10580 13070 11520 14015

13000 118

2900

3500

13360 16310 13940 16895 12990 15940 13805 16755

Other combinations/values on request.

Required NPSH values The following table shows the required NPSH values to ensure that the various pump sizes can be operated without cavitation. These values are derived from the pump kinematics during operation with a low-volatility pumped liquid such as lubricating oil or hydraulic liquid. The following examples indicate that when pumped liquids have a readily volatile component content the required NPSH values notably increase:

□ □

Fuel oil requires an NPSH value of at least 6 mWC. When the pumped liquid contains water (e.g. heavy fuel oil), the values in the table have to be increased by the vapor pressure of the water at the specified operating temperature.

The required NPSH values also needs to be increased if there are gas contents, regardless of whether it is dissolved or not. In case of any doubt, please contact KRAL.

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Pump

Viscosity

Rotation speed [min-1]

size

[mm2/s]

1450 1750 2900 3500 size

Pump

Viscosity

Rotation speed [min-1]

[mm2/s]

1450 1750 2900 3500

NPSH value [mWC] K 55

K 74

K 85

Catalog

6

2.0

37

2.0

152

2.1

380

2.5

6

NPSH value [mWC] K 105

6

2.0

2.7

37

2.0

2.8

3.3

152

3.5

4.0

380

2.0

2.6

3.0

6

37

2.0

2.9

3.4

152

2.3

2.5

3.3

380

2.7

3.0

4.4

6

2.0

2.8

3.4

37

2.0

3.1

3.8

152

2.4

2.6

3.8

4.6

380

2.8

3.1

4.6

5.8

2.7

2.7

3.2

2.2

3.0

3.6

2.4

2.6

3.6

4.4

2.8

3.1

4.4

5.4

2.0

3.1

3.9

37

2.2

3.5

4.4

4.1

152

2.5

2.8

4.3

5.4

5.0

380

3.0

3.3

5.3

6.8

K 118

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Technical data

Required NPSH values

Technical data

Weights Weights Part

Weight [kg]

Station block with reversing valve

37.5

Counter flanges, 2 pc.

2.4

Base frame with oil pan

21.0

Filling volume

Filling volume of the station block [l]

1.8

Noise levels Maximum noise level ±3 [dB(A)] K 55 – 118

12

1 pump

2 pumps

Motor

1 pump + motor

2 pumps + 2 motors

61

64

65

67

70

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Catalog

Dimensions DKB Standard Station size DKB

Pump size

3000 – 13000

KFT 55 – 118

Motor size

DNs / DNd

H1

H2

H3

L1

L2

B1

S1

[mm] [mm] [mm] [mm] [mm] [mm]

80

736

242

142

653

190

85

M16

90

779

242

142

653

190

85

M16

840

242

142

703

190

85

M16

963

242

142

753

190

85

M16

1113 242

142

803

190

85

M16

100/112 132

SAE 2" 3000 PSI

Dimensioned drawings

160

H1

Dimensioned drawings DKB Standard

H3

H2

DNs/DNd

B1

L2

S1

115

L1

Catalog

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Dimensioned drawings

Dimensions DKB Standard

Dimensions DKB with oil pan Pump size Motor size

3000 – 13000 KFT 55 – 118

DNs / H1 H2 H3 L1 L2 L3 B1 B2 S1 DNd [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]

80

828

333

233

—

800

760

400

260

18

90

871

333

233

—

800

760

400

260

18

932

100/112 132

SAE 2" 3000 PSI

Station size DKB

160

333

233

—

800

760

400

260

18

1055 333

233

—

800

760

400

260

18

1205 333

233

803

800

760

400

260

18

Dimensioned drawings DKB with oil pan

H1

L1

10

H3

DNs/DNd

H2

19

L2 L3

14

DKB Edition 03/2010

B1

S1

B2

Dimensioned drawings

Dimensions DKB with oil pan

Catalog

Options

Options

Overview Overview Option

Option

Suction-side pressure monitoring

Oil pan

Temperature monitoring

Electric heating system

Leak oil monitoring

Fluid heating system

Betrieb Entriegeln Alarm Prüfen Alarmton

aus ein

Pressure switch

Catalog

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Options

Suction-side pressure monitoring Suction-side pressure monitoring

In order to monitor the pressure on the suction sides of the two pumps, two further pressure gauges 1 can be mounted optionally.

1 1 1 Fig. 1

16

Suction-side pressure gauge

Pressure monitoring

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Catalog

Temperature monitoring In order to monitor the temperature of the pumped liquid, two thermometers 1 that are mounted at the station block near the two suction connections are available optionally.

1

1 1

Fig. 2

Catalog

Thermometer

Temperature monitoring

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Options

Temperature monitoring

Options

Leak oil monitoring Leak oil monitoring

1 2 3 4 5

Betrieb Entriegeln Alarm

9

Prüfen Alarmton

aus ein

6 7

1 2 3 4 5 6 7 8 9 10

3m

8

230VAC 50Hz

ϑ 10

Fig. 3

Operation Unlock Alarm Test Alarm sound Off On Cable Indication device PTC resistor sensor

Leak oil monitoring

The leak oil monitoring device consists of the indication device and a PTC resistor sensor. The indication device contains the components for optical and acoustical alarm indication as well a potential-free change-over switch for controlling additional signal equipment. When the PTC resistor that is heated up in its operating state is immersed into oil, it cools down, thus triggering an alarm. The leak oil monitoring device is not suitable for heavy-oil applications. We recommend using the leak oil monitoring device with an elevated oil pan. Technical data Power connection

230 V AC, 50 Hz, 10 VA

Outputs

□ □ □

18

1 optical alarm (red lamp) 1 acoustical alarm, can be deactivated (buzzer) 1 potential-free change-over switch for external message, max. 230 V AC, 3 A

Operating temperature

-5...+40 °C

Casing dimensions

163 x 97 x 62 mm

Degree of protection

II

Degree of protection

IP41

Mounting

Wall mounting

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Catalog

Options

Pressure switch Pressure switch It is optionally possible to install pressure switches 1 on the rear of the pumps as an additional pressure monitoring device.

1

1 Fig. 4

Pressure switch

Pressure switch

Specifications of the pressure switch Figure

Characteristic

Data

Sensor: Measuring range: Output:

FKM diaphragm 1 – 16 bar Potential-free change-over contact Large, cannot be adjusted ±0.5...±2.0 % of range, typ. 0...+80 °C 0...+80 °C -40...+80 °C IP65*

Dimensions

Differential gap: Reproducibility: Temperature range: Liquid temperature: Storage temperature: Degree of protection:

A

*only valid with cable socket mounted in accordance with regulations

A Pressure connection Pressure connection

Differential gap approx. *: Operating pressure max.: Pressure connection: Tightening torque:

0.4 – 1.7 200 bar G1/4"; inside 32 – 40 Nm

A

A Pressure connection

Catalog

* depending on set setpoint

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Options

Pressure switch

Figure

Characteristic

Data

Device plug: Cable socket: - Cable ø: - Screw terminals:

DIN43650-A

Electrical connection

6 – 13 mm 4 x 0.5 – 1.5 mm2

Microswitch Switching capacity AC: Switching capacity DC:

250 V 10 (3) A 250 V 0.1 (0.05) A 220 V 0.25 (0.2) A 110 V 0.5 (0.3) A 24 V 2 (1) A Insulation resistance: > 2 MW Dielectric strength: 2 kV to chassis ground Service life (mechanical): 1 million load cycles

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Options

Oil pan Oil pan The pump station can be supplied optionally with an oil pan.

1 1 Fig. 5

Catalog

Base frame with oil pan

Pump station with oil pan

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Heating system General The pump stations can be equipped optionally with a heating system. We recommend heaters for highviscosity liquids that do not flow sufficiently if not heated. This can result in excessive power consumption or lead to problems arising through cavitation or sealing. The type code provides information about the type, see "Type code", page 7. The following types are available: □ Electric heating system □ Fluid heating system Electric heating system

1

2 1 2 3 4

3 4 5 Fig. 6

5

Connecting cable Heating element Seal ring Screw plug heating element Seal ring

Electric heating system

1

2

4,5

6,5

Ø 10

3-5

M 14 x1,5

Options

Heating system

~ 30

Fig. 7

130

Dimensions in mm

Heating element dimensions

Operating data: Voltage: 230 V Power output: 220 W Frequency: 50/60 Hz Wire cross-section: 2 x 1 mm² Filling volume: 0.22 l

□ □ □ □ □

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Options

Heating system

8

7 Fig. 8

6

8

1 2 3 4 5 6 7 8 9

9

Connecting cable Heating element Seal ring Screw plug heating element Seal ring Station block Heating duct Upper screw plugs heating duct Lower screw plug heating duct

Sectional view heating duct

2

5 4 3 9 1 6

Fig. 9

Position of the heating element

Fig. 10 Heating element installation

The electrical heating system consists of a heating element 2 that is integrated in a heating duct 7 of the station block 6. The output of the heating element corresponds to the radiation and convection losses of the station in the required temperature range so that overheating is not possible. Heating up of the station block after the steady-state condition has been reached:

□ □

Catalog

Station rear: Station front:

approx. 80 K approx. 40 K

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90 80 A

70 ∆T [K]

Options

Heating system

60 50 40 30 B

20 10 0 0

4

8 12 16 20 24 28 32 36 40 44 48 52 56 60 80 ∆t [min]

∆t ∆t A B

Heating-up time Temperature rise Station rear Station front

Fig. 11 Temperature rise after the heating has been switched on

Fluid heating system

1 1 2 2

3

3

Fig. 12 Installation position of the fluid heating system

Fig. 13 Sectional view of fluid heating system

1 2

3

Piping Screw connection for fluid heating system

Heating duct

Operating data: □ Maximum pressure: 16 bar □ Maximum fluid temperature: 180 °C □ Connection: Inserted screw connection straight, outer diameter 22 mm In the case of the fluid heating system the heating fluid passes through a heating duct 3 in the station block, see Fig. 13, page 24. The screw connections 2 required to this purpose are available from KRAL, see "Spare parts", page 28.

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General drawings

General drawings

General drawings General drawings

300 472

304 606.1 739.2

894 901

165.3

729

165.3

611 611.2 611.4 611.3 611.1

729

729

739.1

705 165.2 116

705 739.1 165.2

165.3

729

901

165.1 894

914

Fig. 1

Catalog

Station block

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General drawings

General drawings

529

529 180

180 729 901 894 001

606.2 717

729 717

001 606.2

225

Fig. 2

26

Pump station complete

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Catalog

General drawings

General drawings

493

482

481

607

Fig. 3

Pressure switch position

Fig. 4

Electric heating system

483

Fig. 5

Catalog

Screw connection for fluid heating system

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General drawings

Spare parts Spare parts

28

Spare part Part No.

Spare part Part No.

001

Pump

606.2

Pressure gauge

116

Station block

607

Pressure switch

165.1

Screw plug

611

Non-return valve

165.2

Screw plug

611.1

Threaded ring

165.3

Screw plug

611.2

O-ring

180

Pump bracket

611.3

Sealing washer

225

Base frame with oil pan

611.4

Cylindrical spring

300

Reversing valve lever

705

Counter flange

304

Control plug

717

Thermometer

472

Circlip

729

Flat gasket

481

Heating element

739.1

O-ring

482

Electric heating system

739.2

O-ring

483

Screw connection

894

Hexagon nuts

493

Screw plug

901

Stud screws

529

Motor

914

Socket screws

606.1

Pressure gauge

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Catalog

Catalog

General drawings

Spare parts

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KRAL AG, Bildgasse 40, Industrie Nord, 6890 Lustenau, Austria,Tel.: +43 / 55 77 / 8 66 44 - 0 Fax: +43 / 55 77 / 8 84 33, www.kral.at, E-Mail: [email protected]